HYBRID VEHICLE TRANSAXLE REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Click here.

  2. REMOVE REAR NO. 2 FLOOR BOARD

    Click here

  3. REMOVE REAR DECK FLOOR BOX

    Click here

  4. REMOVE REAR NO. 3 FLOOR BOARD

    Click here

  5. REMOVE DECK FLOOR BOX RH

    Click here

  6. REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE

    Click here

  7. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  8. REMOVE SERVICE PLUG GRIP

    Click here

  9. REMOVE HOOD SUB-ASSEMBLY


    1. B001LON

      Disconnect the washer hose.

    2. Disengage the clamp.

    3. Remove the 4 bolts and hood sub-assembly.

  10. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  11. REMOVE FRONT WHEEL

  12. REMOVE REAR ENGINE UNDER COVER LH (for 2ZR-FXE)

    Click here

  13. REMOVE REAR ENGINE UNDER COVER LH (for 5ZR-FXE)

    Click here

  14. REMOVE REAR ENGINE UNDER COVER RH (for 2ZR-FXE)

    Click here

  15. REMOVE REAR ENGINE UNDER COVER RH (for 5ZR-FXE)

    Click here

  16. REMOVE FRONT LOWER BUMPER ABSORBER (for 2ZR-FXE)

    Click here

  17. REMOVE FRONT LOWER BUMPER ABSORBER (for 5ZR-FXE)

    Click here

  18. REMOVE NO. 1 ENGINE UNDER COVER (for 2ZR-FXE)

    Click here

  19. REMOVE NO. 1 ENGINE UNDER COVER (for 5ZR-FXE)

    Click here

  20. DRAIN COOLANT (for Engine)

    for 2ZR-FXE Click here

    for 5ZR-FXE Click here

  21. DRAIN COOLANT (for Inverter)

    Click here

  22. DRAIN HYBRID TRANSAXLE FLUID

    Click here

  23. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  24. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

    Click here

  25. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  26. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

    Click here

  27. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  28. REMOVE COWL BODY MOUNTING REINFORCEMENT LH (for LHD)

    Click here

  29. REMOVE COWL BODY MOUNTING REINFORCEMENT RH (for RHD)

    Click here

  30. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

    Click here

  31. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  32. REMOVE SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper)

    Click here

  33. REMOVE NO. 2 CYLINDER HEAD COVER (for 2ZR-FXE)

    Click here

  34. REMOVE NO. 2 CYLINDER HEAD COVER (for 5ZR-FXE)

    Click here

  35. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FXE)

    Click here

  36. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 5ZR-FXE)

    Click here

  37. REMOVE WATER HOSE HOSE CLAMP (for 2ZR-FXE)

    Click here

  38. REMOVE WATER HOSE HOSE CLAMP (for 5ZR-FXE)

    Click here

  39. REMOVE INLET AIR CLEANER (for 2ZR-FXE)

    Click here

  40. REMOVE INLET AIR CLEANER (for 5ZR-FXE)

    Click here

  41. REMOVE AIR CLEANER CASE (for 2ZR-FXE)

    Click here

  42. REMOVE AIR CLEANER CASE (for 5ZR-FXE)

    Click here

  43. REMOVE AIR CLEANER HOSE ASSEMBLY (for 2ZR-FXE)

    Click here

  44. REMOVE AIR CLEANER HOSE ASSEMBLY (for 5ZR-FXE)

    Click here

  45. REMOVE INVERTER COVER ASSEMBLY LH (w/ Cover)

    Click here

  46. REMOVE RADIATOR SUPPORT OPENING COVER

    Click here

  47. REMOVE NO. 1 INVERTER BRACKET

    Click here

  48. DISCONNECT ENGINE ROOM MAIN WIRE

    Click here

  49. REMOVE INVERTER COVER

    Click here

  50. CHECK TERMINAL VOLTAGE

    Click here

  51. DISCONNECT FRAME WIRE

    Click here

  52. DISCONNECT GENERATOR CABLE

    Click here

  53. DISCONNECT MOTOR CABLE

    Click here

  54. DISCONNECT NO. 2 ENGINE WIRE

    Click here

  55. INSTALL INVERTER COVER

    Click here

  56. DISCONNECT NO. 2 ENGINE ROOM WIRE

    Click here

  57. DISCONNECT WATER HOSE

    Click here

  58. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  59. SEPARATE INVERTER RESERVE TANK ASSEMBLY (for 2ZR-FXE)

    Click here

  60. SEPARATE INVERTER RESERVE TANK ASSEMBLY (for 5ZR-FXE)

    Click here

  61. REMOVE INVERTER TRAY BRACKET (for 2ZR-FXE)

    Click here

  62. REMOVE INVERTER TRAY BRACKET (for 5ZR-FXE)

    Click here

  63. DISCONNECT NO. 1 RADIATOR HOSE (for 2ZR-FXE)

    Click here

  64. DISCONNECT NO. 1 RADIATOR HOSE (for 5ZR-FXE)

    Click here

  65. DISCONNECT NO. 4 WATER BY-PASS HOSE (for 2ZR-FXE)

    Click here

  66. DISCONNECT NO. 4 WATER BY-PASS HOSE (for 5ZR-FXE)

    Click here

  67. REMOVE RADIATOR PIPE (for 2ZR-FXE)

    Click here

  68. REMOVE RADIATOR PIPE (for 5ZR-FXE)

    Click here

  69. DISCONNECT NO. 3 INVERTER COOLING HOSE (for 2ZR-FXE)

    Click here

  70. DISCONNECT NO. 3 INVERTER COOLING HOSE (for 5ZR-FXE)

    Click here

  71. DISCONNECT NO. 5 INVERTER COOLING HOSE (for 2ZR-FXE)

    Click here

  72. DISCONNECT NO. 5 INVERTER COOLING HOSE (for 5ZR-FXE)

    Click here

  73. DISCONNECT WIRE HARNESS


    1. B001K8K

      Disengage the 2 clamps.

    2. Pull up the lever and disconnect the ECM connector.

    3. B001L79E04
      Text in Illustration
      *a Protective Tape

      Disconnect the 2 engine room junction block connectors.

    4. Using a screwdriver, disengage the 2 claws.

      Tech Tips

      Tape the screwdriver tip before use.

    5. B001MY5

      Disengage the 2 clamps.

    6. B001L3S

      Remove the bolt and disconnect the earth wire from the engine assembly.

    7. B001KQKE03
      Text in Illustration
      *a Green-colored Lock

      Release the green-colored lock and disconnect the electric inverter compressor connector as shown in the illustration.

      CAUTION:

      Wear insulated gloves when performing the procedure.

      Note

      Insulate the electric inverter compressor connector by sealing it with tape.

    8. Disconnect the resolver sensor connector.

      B001LMPE02
      Text in Illustration
      *a Resolver Sensor Connector *b Shift Control Actuator Assembly Connector
      *c Throttle Body Assembly Connector *d Generator Cable Terminal Connector
      *e Engine Coolant Temperature Sensor Connector *f Motor Temperature Sensor Connector

    9. Disconnect the shift control actuator assembly connector.

    10. Disconnect the throttle body assembly connector.

    11. Disconnect the generator cable terminal connector.

    12. Disconnect the engine coolant temperature sensor connector.

    13. Disconnect the motor temperature sensor connector.

    14. Remove the 3 bolts.

    15. Disengage the 12 clamps.

  74. SECURE STEERING WHEEL

    Click here

  75. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  76. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  77. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  78. REMOVE FRONT NO. 3 ENGINE UNDER COVER (for 2ZR-FXE)

    Click here

  79. REMOVE FRONT NO. 3 ENGINE UNDER COVER (for 5ZR-FXE)

    Click here

  80. REMOVE FRONT CENTER FLOOR BRACE (for 2ZR-FXE)

    Click here

  81. REMOVE FRONT CENTER FLOOR BRACE (for 5ZR-FXE)

    Click here

  82. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2ZR-FXE)

    w/ Exhaust Heat Recirculation System Click here

    w/o Exhaust Heat Recirculation System Click here

  83. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 5ZR-FXE)

    Click here

  84. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  85. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  86. SEPARATE FRONT SPEED SENSOR LH

    Click here

  87. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  88. SEPARATE TIE ROD END SUB-ASSEMBLY LH

    Click here

  89. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  90. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  91. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  92. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  93. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  94. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  95. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  96. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  97. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  98. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  99. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING RH

    Tech Tips

    Perform the same procedure as for the LH side.

  100. INSTALL ENGINE HANGERS


    1. B001LOEE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the 2 engine hangers to the engine assembly with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Part Name Part No.
      No. 1 Engine Hanger 12281-37021
      No. 2 Engine Hanger 12282-37011
      Bolt 91552-81050

    2. Attach a sling device to the engine hangers and a chain block.

  101. REMOVE STARTER HOLE INSULATOR


    1. B001LW6

      Remove the 2 bolts and starter hole insulator from the engine assembly.

  102. REMOVE FLYWHEEL HOUSING SIDE COVER


    1. B001KF7

      Remove the flywheel housing side cover from the engine assembly.

  103. REMOVE FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT

    Click here

  104. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  105. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  106. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  107. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  108. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  109. REMOVE REAR ENGINE MOUNTING INSULATOR (for 2ZR-FXE)

    Click here

  110. REMOVE REAR ENGINE MOUNTING INSULATOR (for 5ZR-FXE)

    Click here

  111. SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. Support the hybrid vehicle transaxle assembly with a transmission jack.

  112. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY


    1. B001LYQ

      Remove the bolt and nut from the front engine mounting insulator.

    2. B001KVD

      Remove the 4 bolts and front crossmember subassembly from the vehicle body.

  113. REMOVE FRONT ENGINE MOUNTING INSULATOR (for 2ZR-FXE)

    Click here

  114. REMOVE FRONT ENGINE MOUNTING INSULATOR (for 5ZR-FXE)

    Click here

  115. REMOVE ENGINE MOUNTING BRACKET LH


    1. B001LWB

      Remove the through bolt and nut, and separate the engine mounting insulator LH from the engine mounting bracket LH.

      Note

      Turn the nut while holding the bolt.

    2. B001LX4

      Remove the 3 bolts and engine mounting bracket LH from the hybrid vehicle transaxle assembly.

  116. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. B001MW7

      Remove the 7 bolts and hybrid vehicle transaxle assembly from the engine assembly.

      Note


      • To avoid damage to the knock pins, do not pry between the hybrid vehicle transaxle assembly and engine assembly.

      • To prevent the splines of the damper from becoming misaligned, do not allow the hybrid vehicle transaxle assembly to hit the damper during hybrid vehicle transaxle assembly removal and installation.

  117. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. B001MQN

      Remove the 3 bolts and front engine mounting bracket from the hybrid vehicle transaxle assembly.

  118. REMOVE REAR ENGINE MOUNTING BRACKET


    1. B001MU3

      Remove the 4 bolts and rear engine mounting bracket from the hybrid vehicle transaxle assembly.

  119. REMOVE WIRE HARNESS CLAMP BRACKET


    1. B001LBQ

      Remove the 2 bolts and 2 wire harness clamp brackets from the hybrid vehicle transaxle assembly.

  120. REMOVE MOTOR CABLE BRACKET


    1. B001KC4

      Remove the bolt and motor cable bracket from the hybrid vehicle transaxle assembly.

  121. REMOVE GENERATOR CABLE

    Click here

  122. REMOVE MOTOR CABLE

    Click here